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DME would like to congratulate all project participants for West Pharmaceutical Services, Inc.’s Kinston, NC expansion project, which recently received an honorable mention for the ISPE Facility of the Year Award (FOYA). The FOYA committee is awarding West an honorable mention for their industry leading efforts to align primary components manufacturing process with current industry trends and standards.

About the Project
As biopharmaceutical companies continue to bring new molecular entities to market, components play a significant role in preserving the integrity and efficacy of drugs. In addition, regulators are paying more attention to components that come into direct contact with the drugs. Vials, stoppers and syringes, if not properly manufactured, processed, packaged, and shipped, have the potential to render pharmaceutical products adulterated or contaminated.

West is a primary component supplier that is raising the bar on how these components are manufactured. The facility expansion project was designed with transparency and compliance in mind.

  • A new glass wall system makes the process visible to customers, eliminating the need for visitors to gown and enter controlled areas, while minimizing production interruptions and contamination concerns.
  • Phones are strategically located so customers can ask questions, in real time, while manufacturing processes are taking place.
  • Enhanced HVAC and environmental monitoring systems allow West to tightly control its production environment ensuring quality products for customers.
  • Special care was taken to introduce a clean room design that has become the standard within the entire West network.
Horst Construction’s Role
Construction partner Horst led the way, providing leadership and direction to the design-build team—including all subcontractors and suppliers—in what became a complex and well-orchestrated multi-phase scope.

Because the expansion required use of the existing parking area, phase one included a new parking lot, in addition to relocation of sewer lines, storm water management, and fire lines. Next was the relocation of the employee entrance area, installation of the hallways, and relocation of the lab. Phases three and four included installation of a high rise racking system in the warehouse to better organize stored materials, ESFR sprinkler systems, reworking the HVAC in the existing warehouse, preparation of the pad for the addition, and relocation of utilities.

Next was construction of the shell, concrete footings, steel columns, and roofing. Phase six comprised the fit-out, including 13 new air handler units, 8 clean rooms, WFI water room, lab suite, and showcase quality floor to ceiling glass walls.

DME’s Role
DME’s role included HVAC design for cleanroom and clean non-classified manufacturing, support, and warehouse spaces. The central plant system upgrades included HVAC piping distribution, general utility piping, process utility piping, plumbing, fire protection, and power systems. Adding a 750-ton centrifugal chiller, a 250 BHP high-pressure steam boiler, and a 300 HP oil free water-cooled air compressor expanded the central plant utility capacity.

DME also designed a new 4000A, 480/277V electrical service entrance to provide adequate power for new building systems and process equipment loads, as well as a new switchboard. A new natural gas-fired emergency generator accommodated emergency lighting, as well as specific production and lab equipment.

Key Project Participants
  • Designer/Architect: Eric Walker, AIA, CCS
  • Engineer: DME
  • Construction Manager/Main/General Contractor: Horst Construction
  • Piping Subcontractor/HVAC Subcontractor: Gamewell Mechanical
  • Automation and Control Supplier: Siemens
  • Major Equipment Supplier(s)/Contractor(s): Temtrol, Inc.; Carrier Commerical Services

Congratulations to all participants! The FOYA awards will be celebrated on June 7th, 2016 during the ISPE Quality Manufacturing Conference in North Bethesda, Maryland.

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